Page 1

WORKSHOP MANUAL Code 57.4400.4200 - 1st Edition 12/2002

Handler with telescopic boom

GIROLIFT 3514 - GIROLIFT 3518 GIROLIFT 5022

English Edition

INDEX


GIROLIFT Series CONTENTS

5

MANUAL CONTENTS Sect. A GENERAL INFORMATION Sect. B SAFETY REGULATIONS Sect. C TECHNICAL OPERATION DATA Sect. D CHECKS AND ADJUSTMENTS Sect. E DISASSEMBLIES AND ASSEMBLIES Sect. F TROUBLESHOOTING Sect. G DANA AXLE ASSEMBLY/DISASSEMBLY Sect. H PERKINS ENGINE MAINTENANCE Sect.

I REPAIR INSTRUCTIONS - REXROTH PUMP

Sect. L REPAIR INSTRUCTIONS - REXROTH PUMP Sect. M REPAIR INSTRUCTIONS - REXROTH MOTOR Sect. N DANA GEARBOX ASSEMBLY/DISASSEMBLY Sect. O ROTATION REDUCTION GEAR ASSEMBLY/DISASSEMBLY Sect. P MAINTENANCE INSTRUCTIONS - 3B6 LOAD LIMITER

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION

1

Section A GENERAL INFORMATION SECTION INDEX A.01

Introduction ......................................................................................... page

2

A.02

Symbols used in the manual .......................................................................

3

A.03

Abbreviations ................................................................................................

4

A.04

Units of measure ..........................................................................................

5

A.05

Minimum workshop equipment ..................................................................

6

A.06

Special equipment .......................................................................................

7

A.07

Bolt and nut tightening torques ..................................................................

11

A.08

Drill diameters for threads ..........................................................................

13

A.09

Fitting tightening torques ............................................................................

14

A.10

Locking materials.........................................................................................

16

A.11

Hoisting instructions ....................................................................................

17

A.12

Weight list of the main parts .......................................................................

18

A.13

Advice to renew flexible hoses ...................................................................

19

A.14

Repair interventions, welds and weld materials .......................................

20

A.15

Weld material ................................................................................................

23

A.16

Checks with liquid penetrants ....................................................................

24

A.17

Checks with magnetoscope .......................................................................

25

A.18

Refilling and product specifications ...........................................................

26

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.01

2

INTRODUCTION

This manual has been prepared to provide information about the routine and extraordinary maintenance of the main units of the machine in a safe and proper way. STRICTLY COMPLY WITH THE INSTRUCTIONS GIVEN IN THIS MANUAL! READ AND UNDERSTAND THIS MANUAL BEFORE CARRYING OUT ANY INTERVENTION ON THE MACHINE. If you are unsure about anything after the reading of this manual, address to TEREXLIFT Assistance Service: addresses, phone and fax numbers are printed in the cover and in the title-page of this manual. Keep this manual in the workshop at all times and read it before carrying out any extraordinary maintenance job.

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION

3

A.02 SYMBOLS USED IN THE MANUAL In this manual, any important information starts with a SPECIAL SYMBOL. Symbols are also used to direct the reader's attention to special technical information about the tools to use, the tightening torques, etc. There are six safety symbols in this manual, always combined with keywords that class the situations according to their degree of dangerousness. The symbols are always followed by a text explaining the situation taken into account, the attention to be paid to such situation, the method and the behaviour to be adopted. If necessary, it stresses prohibitions or provides instructions to prevent dangers. Sometimes, it can be followed by illustrations. The safety symbols are the following:

DANGER Draws the attention to situations that involve your own as well as the others’ safety and that can result in serious or lethal injury.

ELECTRICAL DANGER Draws the attention to electrical risks that involve your own as well as the others’ safety and that can result in serious injury or lethal injury.

ATTENTION Draws the attention either to situations that involve your own as well as the others’ safety and that can result in minor or moderate injury; or to situations that affect the machine efficiency.

IMPORTANT Draws the attention to important technical information or practical advice that allows for a safer and more efficient use of the machine.

PROTECT THE ENVIRONMENT Draws the attention to important environment-related information.

Indicates the number of people needed for the job

Time expected to do the intervention (except in case of troubles)

CAUTION Draws the attention either to situations that involve your own as well as the others’ safety and that can result in minor or moderate injury; or to situations that affect the machine efficiency.

Special tools needed for the job

Weight of the unit to be handled

Tightening torque of bolts and screws

Inspection needed

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.03

4

ABBREVIATIONS

Abbreviation

Definition

Tab. Pag. Sect. Dwg. Ref. CLS Mach. Fig. Ph. T.O. T.A.S.

Table Page Section Drawing Reference Concrete Machine Figure Photo Technical Office Technical Assistance Service

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.04 UNITS OF MEASURE

1 FORCE The unit of measure of force is the Newton (N) For the conversion: 1N = 0.1019 kg 1 kg = 9.81 N 2 POWER The unit of measure of power is the kilowatt (kW). Other units of measure used are: CV Horsepower HP Horsepower For the conversion: 1 kW = 1.36 CV 1 kW = 1.34 HP 1 CV = 0.736 kW 1 CV = 0.986 HP 1 HP = 0.746 kW 1 HP = 1.014 CV 3 TORQUE The unit of measure of power is the Newton metre (Nm). For the conversion: 1 Nm = 0.1019 kgm 1 kgm = 9.81 Nm 1 kgm = 10 Nm NOTE: For simplicity, the Nm unit is converted according to the ratio 10 Nm = 1 kgm 4 SPECIFIC CONSUMPTION The specific consumption is expressed in g/kWh (grams per kilowatt-hour). Another unit of measure used is: g/HPh (grams per horsepower-hour) For the conversion: 1 g/kWh = 0.736 g/HPh 1 g/HPh = 1.36 g/kWh

Document 57.4400.4200 - 1st Edition 12/2002

5

5 PRESSURE The unit of measure of pressure is the kPa (kilopascal). Other units of measure used are: kg/cm2 kilogram per square centimetre Atm Technical atmosphere psi Pound per square inch For the conversion: 1 kg/cm2 = 1 Atm 98.1 kPa 1 kg/cm2 = 2 1 kg/cm = 0.981 bar 2 1 bar 1 kg/cm = 1 kg/cm2 = 14.22 psi 1 bar = 100 kPa 1 bar = 1.02 kg/cm2 1 bar = 14.51 psi 1 psi = 6.9 kPa 1 psi = 0.069 bar 1 psi = 0.0703 kg/cm2 1 kPa = 0.145 psi 1 kPa = 0.0102 kg/cm2 1 kPa = 0.01 bar NOTE: For simplicity, the bar unit is converted according to the ratio 1 bar = 1 kg/cm2 6 CONVERSION OF SOME METRIC UNITS OF MEASURE INTO IMPERIAL UNITS OF MEASURE 0.1 mm = 3.937 mils 1 mm = 0.039 inch 1m = 3.281 ft 1 km = 0.621 miles 3 1 cm = 0.061 cu. in. 1g = 0.035 oz. 1 kg = 2.205 lbs. 1t = 1.102 short ton 1t = 0.9842 long ton 0째C = 32째F Note: in case of differences of temperature 1째C = 1.8째F

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.05 WORKSHOP EQUIPMENT

IMPORTANT The list below indicates the minimum equipment necessary for servicing the vehicle. Standard tools • 6 to 41 mm box wrench set • 6 to 41 mm socket wrench set • 2 to 10 mm Allen wrench set • External circlip pliers - ø 10÷60 mm • Internal circlip pliers - ø 20÷200 mm • Two-leg pullers - ø 25÷200 mm • Three-leg pullers - ø 50÷400 mm • American cutters • Scissors • Screwdriver set • Hammer set • Mallets with plastic plugs • Combination pliers • Wire nippers • Nylon collar pliers • Wire cutter • Wire strippers • Shears • Cutting nippers • Hand-saw • Cutter • Slotted screw driver set - ø 2.5 ÷ 10 mm • Crosshead screw driver set - ø 2.5 ÷ 10 mm • Adjustable self-locking pliers • Ring nut spanner • Wrench set for hydraulic cylinders • Drift bolt set • Chisel set • Punch • Funnel • Funnel with flexible extension • Calibrated measuring beaker • Crowbar • Fluid collecting tanks • Pliers for internal cylinder seals Fittings for plugging disconnected pipes • 1/4" gas male plug • 3/8" gas male plug • 1/2" gas male plug • 1" gas male plug • 1" 1/4 gas male plug • 1" 1/2 gas male plug • 1/4" gas female plug • 3/8" gas female plug

Document 57.4400.4200 - 1st Edition 12/2002

• • • •

6

1/2" gas female plug 1" gas female plug 1" 1/4 gas female plug 1" 1/2 gas female plug

Sealing material • Teflon tape • Loctite sealant • Loctite threadlocker Equipment and instrumentation • Measure instruments: metre, gauge, micrometres • Compressor with compressed air system • Hydraulic circuit test bench for pressures up to 400 bar • Pressure gauges 0-60 bar / 0-240 bar / 0-600 bar • Ammeter • Digital tester • Hourmeter • Hydrometer for checking the battery charge • Thermometer for oil temperature check • Lamp/indicator for checking hydraulic circuit leaks • Painting system • Steam cleaner • Forklift and/or pallet lift • Stackable wooden planks and/or pallets • Electric welding machine • Cylinder and blowpipe • Hoisting means with 5000 kg payload • Textile bridles • Two-/three-leg chains with hooks • Pneumatic screwdriver • Water level • Bench drilling machine • Portable electric drill • Set of helical bits • Set of screw taps and threaders • Battery charger • Adjustable stands Consumable material • Oils • Greases • Rags for cleaning Personal protection equipment • Goggles • Gloves • Ear-protectors • Shoes • Overall

INDEX


A

GIROLIFT Series GENERAL INFORMATION

7

A.06 SPECIAL EQUIPMENT PART#

DESCRIPTION Pressure gauge for checking the hydraulic oil low pressure - 0รท60 bar

Pressure gauge for checking the hydraulic oil medium pressure 0รท240 bar

Pressure gauge for checking the hydraulic oil high pressure 0รท600 bar

Amperometric detector

Electronic hourmeter

Tester for electric values

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION PART#

8

DESCRIPTION Clock / chronometer

Hydrometer for battery charge

Lamp/indicator for hydraulic circuit leaks

Lamp/indicator for electric circuit

Thermometer for checking the freezing point of the radiator coolant

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION PART#

9

DESCRIPTION

Dwg.01

Wooden block for supporting the lifting jack

Dwg.02

Fixed supporting stands for boom

R=90

~18

520 40 200

200

4000

180

0

90

100

0

Wrench for internal seals

Wrench for boom sliding blocks

65

Dwg.03

20 sp.3 70

15

3

100

30

100

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION PART# Dwg.04

27 ø 25x2 L=500

10

DESCRIPTION Wrench for assembling flexible hoses on the block valve of the 3rd telescope extension cyclinder

ø 45 20x10 L=400 Sp. 15

Tester -pressurizer for accumulators

Dwg.05 Parte dagrind molare Part to

Wrench for Hydromatic pumps fixing screws (grind to enter the seat)

Part da to grind Parte molare

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION

11

A.07 TIGHTENING TORQUES Thread diameter

Pitch

Wrench measure mm S

mm

mm

Tightening torques Material class

S UNI 5931/32

UNI 5933รท36

8.8

UNI 5923รท30

10.9

12.9

Normali

Zincate

Normali

Zincate

Normali

Zincate

Nm

Nm

Nm

Nm

Nm

Nm

4

0,7

7

3

2,5

2

3,2

2,8

4,4

3,9

5,3

4,8

5

0,8

8

4

3

2,5

6,1

5,5

8,7

7,8

10,3

9,3

6

1

10

5

4

3

10,6

9,5

14,8

13,3

17,8

16,0

8

1,25

13

6

5

4

25,1

22,5

35,4

31,8

42,5

30,2

1

13

6

5

4

26,5

23,8

37,3

33,5

44,7

40,3

1,5

17

8

6

5

51,1

46,0

71,9

64,7

86,3

77,6

1,25

17

8

6

5

53,4

48,1

75,1

67,5

90,2

81,1

1,75

19

10

8

6

86,5

77,8

121,4

109,2

145,9

131,3

1,25

19

10

8

6

92,4

83,2

129,5

116,6

156,1

140,5

2

22

12

10

6

137,7

123,9

193,8

174,4

232,6

209,3

1,5

22

12

10

6

145,9

131,3

206,1

185,5

246,9

222,0

2

24

14

10

8

209,1

188,2

293,8

264,4

353,0

317,7

1,5

24

14

10

8

218,3

196,5

308,1

277,3

369,3

332,4

2,5

27

14

12

8

288,7

259,8

406,1

365,5

487,7

436,9

1,5

27

14

12

8

314,2

282,8

442,8

398,5

530,6

477,5

2,5

30

17

12

10

408,1

367,3

573,4

516,1

687,7

618,9

1,5

30

17

12

10

439,7

395,8

619,3

557,4

742,8

662,5

2,5

32

17

-

12

542,3

488,5

763,2

686,9

915,3

823,7

1,5

32

17

-

12

582,6

524,3

819,3

737,4

983,6

885,3

3

36

19

-

12

705,1

634,5

990,8

891,7

1193,3

1074,4

2

36

19

-

12

745,3

671,3

1051,0

945,9

1255,1

1129,5

3

41

19

-

-

1036,0

927,5

1448,9

1304,0

1734,6

1561,2

2

41

19

-

-

1091,8

982,6

1530,6

1377,5

1836,7

1653,0

3,5

46

22

-

-

1307,9

1258,1

1989,3

1772,4

2357,1

2121,4

2

46

22

-

-

1510,2

1359,1

2122,4

1910,2

2540,8

2286,7

3,5

50

24

-

-

2000,0

1800,0

2800,0

2520,0

3400,0

3060,0

2

50

24

-

-

1610,0

1450,0

2300,0

2070,0

2690,0

2420,0

4

55

27

-

-

2600,0

2340,0

3700,0

3330,0

4300,0

3870,0

3

55

27

-

-

2800,0

2520,0

3900,0

3510,0

4600,0

4140,0

4

60

27

-

-

3400,0

3060,0

4800,0

4320,0

5600,0

5040,0

3

60

27

-

-

3600,0

3240,0

5100,0

4590,0

5900,0

5310,0

10

12

14

16

18

20

22

24

27

30

33

36

39

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION Thread diameter

Pitch

Standard nuts

Low nuts

5S

8G

5S

8G

Nm

Nm

Nm

Nm

4

0,7

5,5

3,5

5

0,8

5,5

3,5

6

1

9,5

13,0

6,0

8,0

8

1,25

23,0

32,0

14,0

20,0

1

25,0

35,0

16,0

22,0

1,5

46,0

64,0

29,0

40,0

1,25

49,0

68,0

31,0

42,0

1,75

80,0

110,0

50,0

69,0

1,25

88,0

125,0

55,0

78,0

2

125,0

180,0

78,0

110,0

1,5

140,0

195,0

88,0

120,0

2

195,0

275,0

120,0

170,0

1,5

210,0

295,0

130,0

185,0

2,5

270,0

390,0

170,0

245,0

1,5

305,0

425,0

190,0

265,0

2,5

305,0

540,0

190,0

340,0

1,5

425,0

600,0

260,0

375,0

2,5

510,0

720,0

320,0

450,0

1,5

570,0

800,0

360,0

500,0

3

660,0

930,0

410,0

580,0

2

720,0

1000,0

450,0

630,0

3

980,0

1400,0

610,0

880,0

2

1050,0

1500,0

660,0

940,0

3,5

1350,0

1850,0

850,0

1160,0

2

1450,0

2050,0

910,0

1280,0

3,5

1650,0

2310,0

1050,0

1470,0

2

1980,0

2770,0

1270,0

1780,0

4

2120,0

2970,0

1360,0

1900,0

3

2550,0

3570,0

1630,0

2280,0

4

2730,0

3820,0

1750,0

2450,0

3

3250,0

4550,0

2080,0

2910,0

10

12

14

16

18

20

22

24

27

30

33

36

39

Document 57.4400.4200 - 1st Edition 12/2002

12

INDEX


A

GIROLIFT Series GENERAL INFORMATION

13

A.08 DRILL DIAMETERS FOR THREADS Thread x pitch

DRILL DIAMETER LIMITS max min

DRILL BIT DIAMETER

M 4 x 0,7

3,42

3,24

3,30

x 0,5

3,60

3,46

3,50

M 5 x 0,8

4,33

4,13

4,20

x 0,5

4,60

4,46

4,50

M6x1

5,15

4,92

5,00

x 0,75

5,38

5,19

5,20

M 8 x 1,25

6,91

6,65

6,80

x1

7,15

6,92

7,00

M 10 x 1,5

8,87

8,38

8,50

x 1,25

9,38

9,19

9,20

M 12 x 1,75

10,44

10,10

10,20

x 1,5

10,68

10,38

10,50

M 14 x 2

12,21

11,83

12,00

x 1,5

12,68

12,38

12,50

M 16 x 2

14,21

13,84

14,00

x 1,5

14,68

14,38

14,50

M 18 x 2,5

15,74

15,29

15,50

x 1,5

16,68

16,38

16,50

M 20 x 2,5

17,74

17,29

17,50

x 1,5

18,68

18,38

18,50

M 22 x 2,5

19,74

19,29

19,50

x 1,5

20,68

20,38

20,50

M 24 x 3

21,25

20,75

21,00

x2

22,21

21,83

22,00

M 27 x 3

24,25

23,75

24,00

x2

25,21

24,83

25,00

M 30 x 3,5

26,77

26,21

26,50

x3

27,25

26,75

27,00

M 33 x 3,5

27,77

29,21

29,50

x2

31,21

30,83

31,00

M 36 x 4

32,27

31,65

32,00

x3

33,25

32,75

33,00

M 39 x 4

35,27

34,67

35,00

x3

36,25

35,75

36,00

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.09 STANDARD TIGHTENING TORQUES FOR FITTING SEALS ■

FRONT O-LOK (Parker) SEALS Thread diameter

60° CONICAL SEALS Thread diameter

TIGHTENING TORQUES (0+10%)

inc.

60° CONICAL SEALS Nm

14

TIGHTENING TORQUES

mm

FRONT O-LOK (Parker) SEALS Nm

9/16"-18

25

11/16"-16

40

15

13/16"-16

55

20

1"-14

80

9/16"-18

25

1.3/16"-12

115

11/16"-16

40

1.7/16"-12

130

13/16"-16

55

1.11/16"-12

190

3/4"-16

62

2"-12

245

1"-14

80

7/8"-14

80

1.1/16"-12

110

1.3/16"-12

115

1.5/16"-12

160

1.7/16"-12

130

1.11/16"-12

190

1.5/8"-12

225

1.7/8"-12

270

2"-12

245

2.1/4"-12

360

inc.

mm

G 1/8" G 1/4"

M 10 x 1

37° COUNTER-SUNK CONICAL SEALS (JIC) Thread diameter

inc.

TIGHTENING TORQUES (0+10%)

mm

7/16"-20

M10x1

15

1/2"-20

M12x1.5

20

9/16"-18

M14x1.5

28

M16x1.5

62

3/4"-16

M18x1.5

62

7/8"-14

M22x1.5

80

1.1/16"-12

M27x2

110

1.3/16"-12

Document 57.4400.4200 - 1st Edition 12/2002

37° CONICAL SEALS (JIC) Nm

141

1.5/16"-12

M33x2

160

1.5/8"-12

M42x2

225

1.7/8"-12

M48x2

270

2.1/4"-12

M10x1

360

INDEX


A

GIROLIFT Series GENERAL INFORMATION ■

SEALS WITH GRIP-RING Thread diameter

inc.

mm

Fitting Series

Pipe ø mm

TIGHTENING TORQUE (0+10%) SEALS WITH GRIP-RING Nm

G 1/8"

M10x1

LL

4

10

G 1/8"

M10x1

LL

6

10

G 1/8"

M10x1

L

6

25

G 1/4"

M12x1.5

L

8

50

G 1/4"

M14x1.5

L

10

50

G 1/8"

M20x1.5

L

12

130

G 1/8"

M20x1.5

L

15

190

G 1/8"

M20x1.5

L

18

245

G 1/8"

M20x1.5

L

22

130

G 1/8"

M20x1.5

L

28

190

G 1/8"

M20x1.5

L

35

245

G 1/8"

M20x1.5

L

42

245

G 1/4"

M12x1.5

S

6

50

G 1/4"

M14x1.5

S

8

50

G 3/8"

M16x1.5

S

10

80

G 3/8"

M18x1.5

S

12

80

G 1/2"

M22x1.5

S

16

105

G 3/4"

M27x2

S

20

220

G 1"

M33x2

S

25

370

G 1.1/4"

M42x2

S

30

500

G 1.1/2"

M48x2

S

38

600

15

FITTING ASSEMBLY Thread diameter

TIGHTENING TORQUES (0+10%) JOINTS

inc.

mm

A Nm

G 1/8"

M10x1

25

12

M12x1.5

30

18

40

18

M14x1.5

50

20

M16x1.5

60

35

M18x1.5

80

50

95

40

M20x1.5

140

60

M22x1.5

140

75

M26x1.5

220

85

250

110

250

100

400

190

400

150

600

240

600

260

800

300

800

350

G 1/4"

G 3/8"

G 1/2"

G 3/4" M27x2 G 1" M33x2 G 1.1/4" M42x2 G 1.1/2" M48x2

A

Document 57.4400.4200 - 1st Edition 12/2002

B

A

Male face Mechanical seal or copper washer

B

Male face Soft seal with O-ring

INDEX

B Nm


A

GIROLIFT Series GENERAL INFORMATION

16

A.10 LOCKING MATERIAL THREADLOCKERS Product

APPLICATION

Characteristics Temp. °C Thread

Locking speed

Resistance

Loctite 290

Thread locking

to 150°

M 12

Rapid

Medium

Loctite 222

Thread locking

to 150°

M 20

Moderate

Low

Loctite 243

Thread locking

to 150°

M 20

Rapid

Medium

Loctite 262

Thread locking

to 150°

M 20

Moderate

High

Loctite 270

Thread locking

to 150°

M 20

Moderate

Very high

Loctite 277

Thread locking

to 150°

M 36

Slow

High

Loctite 272

Thread locking

to 200°

M 36

Slow

High

THREAD SEALANT

For hermetic sealing. Non suitable for thermoplastic materials

Product

APPLICATION

Characteristics max Thread °C max type

Loctite 511

Fitting sealant

150°

M80

Con./Cyl.

Rapid

Low

Loctite 542

Fitting sealant

150°

M36

Con./Cyl.

Rapid

Moderate

Loctite 545

Fitting sealant

150°

M36

Con./Con.

Moderate

Low

Loctite 565

Fitting sealant

150°

M80

Con./Cyl.

Instantaneous

Low

Loctite 572

Fitting sealant

150°

M80

Con./Cyl.

Moderate

Low

Loctite 577

Fitting sealant

150°

M80

Con./Cyl.

Rapid

Moderate

GASKETS

Locking speed

Disassembly difficulty

Total sealing in 24-72 hours

Product

APPLICATION

Characteristics max Play °C max mm

Formation time

Resistance to fluids

Loctite 518

Formed-in-place gasket

150°

0,5

Moderate

Excellent

Loctite 509

Formed-in-place gasket

150°

0,2

Moderate

Excellent

Loctite 573

Formed-in-place gasket

150°

0,2

Slow

Excellent

Loctite 574

Formed-in-place gasket

150°

0,5

Rapid

Excellent

Loctite 510

Formed-in-place gasket

200°

0,2

Moderate

Excellent

Loctite 5699

Formed-in-place gasket

200°

6,0

Rapid

Excellent

Loctite 5999

Formed-in-place gasket

200°

6,0

Instantaneous

Excellent

Loctite 5910

Formed-in-place gasket

200°

6,0

Rapid

Excellent

Loctite 5900

Formed-in-place gasket

200°

6,0

Instantaneous

Excellent

Loctite 5920

Formed-in-place gasket

250°

M 36

Slow

Good

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.11 HOISTING INSTRUCTIONS

Attach the load to the natural seat of the hook. Attacching a load to an end can cause the load to fall down during raising and result in serious injury.

DANGER All parts weighing more than 25 kg MUST COMPULSORILY be handled with suitable hoisting means. In the Disassembly and Assembly section there is a clear indication of the weight of the part to handle, while chapter A.12 contains a summary table with the weight of the single components. Before removing parts of the machine, make sure that: • all fixing bolts have been removed • all hydraulic and electrical parts have been disconnected • the part to be removed is not blocked. STRANDED ROPES • Use ropes or other hoisting accessories suitable to the weight of the part to be handled. For ropes, refer to the following table:

Rope diameter mm 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60

STRANDED ROPES Max admissible load kg 1000 1400 1600 2200 2800 3600 4400 5600 10000 18000 28000 40000

17

P

P

P

P

P

100%

88%

79%

71%

41%

Do not attach a heavy load to ropes forming a wide suspension angle. The total capacity of the ropes reduces proportionally to the amplitude of the angle as shown in the following chart.

kg 2000

α

1500

kg

1000 500

30°

60°

90°

120°

The value of the admissible load has been considered as equal to 1/6 the rope breaking load.

Document 57.4400.4200 - 1st Edition 12/2002

INDEX

150°

α


A

GIROLIFT Series GENERAL INFORMATION

18

A.12 WEIGHT LIST OF THE MAIN PARTS

❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑

Part Complete cab Base frame without turret Turret 1st boom element 2nd boom element 3rd boom element Complete boom Oil-fuel tank Boom raising cylinder 2nd telescope extension cylinder 3rd telescope extension cylinder Fork balance cylinder Fork movement cylinderc Front axle Rear axle Drive pump Service pump Perkins engine Distributor Gearbox Hydraulic joint Cooler Complete wheel (n° 1) Wheel rim (n° 1) Stabilising foot (n° 1) Turret rotation reduction gear

Weight kg 450 1470 1080 710 430 490 2300 204 278 235 146 40 80 700 700 63 35 550 30 73 100 35 120 40 50 69

DANGER All parts weighing more than 25 kg MUST COMPULSORILY be handled with suitable hoisting means.

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.13 ADVICE TO RENEW FLEXIBLE HOSES

PROTECT THE ENVIRONMENT Before disconnecting the hydraulic piping, place containers of suitable size underneath to prevent oil spillage.

IMPORTANT Plug all disconnected parts to prevent dust or impurities from entering the circuit. They can cause serious damage.

19

1 Before disconnecting or refitting a flexible hose, carefully clean the area all around. 2 Blow some compressed air to remove any impurity. 3 For an easier renewal of the hoses, whose run is not clearly visible, proceed as follows: - disconnect the hose to be replaced from both sides - tie a cord to one end of the hose - remove the hose pulling the cord until it comes out completely - untie the cord and tie it to the new hose - pull the cord from the other side to refit the hose until reaching the connecting point to the line.

DANGER Before disconnecting the hydraulic piping, ensure there is no pressure in the line. In case, release the pressure by operating the control levers with the engine stopped. In any case, disconnect the hydraulic piping with extreme caution and always wear suitable personal protection equipment -e.g. goggles, gloves, facial screen, etc. Wrap up the end of the pipe to be disconnected with some rags and slowly loosen the pipe connector so that air comes out as slow as possible.

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION

20

Useful advice for mounting flexible hoses:

OK NO NO

OK NO

NO

OK OK

NO

OK

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.14 REPAIR INTERVENTIONS WELDS AND WELD MATERIALS

ATTENTION Before any weld on the machine, disconnect and isolate the battery cables and all the connections to positive and negative poles reaching the alternator. The ground cable of the machine must be directly connected to a metal part to be welded.

IMPORTANT According to following specifications, repairable cracks are those with a maximum development of 100 mm which have not altered the normal deformability of the structure (crack edges open).

OPERATION PROCEDURE 1 Clean the area where the crack has been found thoroughly.

21

ATTENTION Warning: the visible apex of the crack is not the real apex. This is usually under the material skin and needs non-destructive methods to be found (liquid penetrants, magnetoscopy or ultrasounds).

IMPORTANT It is also necessary that the operator charged of the checks is authorised to use the inspection instrumentation in accordance to UNI EN 473 standard or equivalent.

3 After inspection and once found the position of the two apices of the crack, grind the material for the entire development of the crack - see

2. Grind 50 mm more than the development of the crack on both sides.

Remove paint, concrete or grease residues from the area. To this end use traditional thinners. Crack apex

2 Using a liquid penetrant (or another nondestructive method) inspect the areas to find the apices of the crack.

Griding wheel

50 mm

Griding to realise

Development of the crack 50 mm

Crack apex

Crack apex

4 Check the ground area with a liquid penetrant see 3. Crack apex

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION The result of this check can provide useful information on the depth of the crack:

Type A

The crack does not exceed to the thickness of the iron sheet Crack depth

Iron sheet thickness

In this case, further grind the crack and check again with a liquid penetrant until the crack has been removed.

a- Use electrodes compatible with the structure material.

b- Create a seam with low voltage (V) and current (A) parameters so as not to alter the structure in the vicinity of the weld. The materials used for the structural elements of the machine have a fine grain structure which, if subject to high thermal loads, can result in a coarsening and, consequently, in a decay of the mechanical characteristics of the base material.

IMPORTANT

Aspect of the part to remove by griding

Iron sheet thickness

Type B

22

It is better to foresee an multi-pass welding with moderate parameters rather than a weld with less passes and high parameters.

The crack exceeds the thickness of the iron sheet

Crack exceeding the thickness

Iron sheet thickness

Preparation after grinding Crack not exceeding the thickness

In this case grind in depth without removing too much material as this would complicate subsequent welding.

WELDING PROCEDURE P2

Aspect of the part to remove by griding

Iron sheet thickness

P1

P1: Bottom pass P2: Filling pass 5 Grind as explained below: PRE-HEAT AT 120° BEFORE PASS P1

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION Preparation after grinding Crack exceeding the thickness

23

If, during this last check, defects in the seams or other defects such as burns or cuts are found:

a- Grind away the defect. b- Check again to be sure the defect has been eliminated with a non-destructive test.

WELDING PROCEDURE

c- Re-weld the defective section as indicated in point 5.

P3

P2

P1

P1: Pass at the root P2: Intermediate pass P3: Filling pass

A.15 WELD MATERIAL

For material S690 (CNR 10029-87) Wire ø 1.2 Class ER100S-G AWS A5.28-79 Protection gas 80% Argon mixture 20% CO2

PRE-HEAT AT 120° BEFORE PASS P1

IMPORTANT IMPORTANT

To weld couplings S690-S690 or S690 with other material, pre-heat:

For reduced thickness values (3-5 mm) the operation can be carried out in two passes eliminated pass P2.

• Recommended: for thickness up to 7.5 mm at 100-120°C • Compulsory: for thickness from 8 mm and more at 150°C

c- The welder must be qualified and use specific materials for the structural elements in accordance with UNI EN 287 or equivalent.

6 After cooling of the welded parts, do a final check with a liquid penetrant to be sure no surface cuts or cracks have been produced during welding. Do a magnetoscopic or ultrasound inspection to be sure there are no internal defects in the material.

Document 57.4400.4200 - 1st Edition 12/2002

For material S490 (CNR 10029-87) Wire ø 1.2 Class DIN 8559-84 SG3 Protection gas 80% Argon mixture 20% CO2

INDEX


A

GIROLIFT Series GENERAL INFORMATION

24

A.16 CHECKS WITH LIQUID PENETRANTS Procedure to check welds or material cracks:

1 Thoroughly clean the part to be checked making

2 3 4

5

sure there are no fluids or anything else which can prevent a good penetration of the fluid; to this end, use sand paper, grinding wheel, dry rags or paper. Use a red liquid and let it dry for about 5 รท 8 minutes Thoroughly clean with a rag and some water or a sponge, then dry with a clean and dry rag Spray a white liquid (detector) onto the part to be checked and let dry for about 5 รท 6 minutes. If after this treatment the red colour comes to surface decidedly there is a crack. Pay extreme attention as, in presence of a deep but close crack, the red colour could hardly come to surface. Pay attention to the area thermally altered by welding since cracks usually appear in this area and not in the middle of the weld.

6 This check can detect any surface crack.

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION A.17 CHECKS WITH MAGNETOSCOPE

Scope: The checks with magnescope allow to find surface and sub-surface cracks down to 2 mm to guarantee the integrity of the structure

Equipment: Magnetoscope

25

Reading of the magnetoscopic image: After magnetising the part and applied the detecting liquid, examine the area to find any indications. Indications of presence of a crack can be found on the edges and in the crack fissure with accumulation of magnetic particles.

IMPORTANT Note all the defects with their position, length and type of indication on the drawing of the examined part to evaluate the damage.

Detection method: Black magnetic powder diluted in water. Spray the mixture onto the part to be checked during the magnetisation of the examined part. Preparation of the surface: The surface must be as regular as possible - e.g. absence of weld drops. The check can also be done on painted surfaces provided they are uniform. Magnetisation mode: The magnetisation of the area to be examined shall be done so that the lines of the magnetic field are perpendicular to the profile (course) of the defect.

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


A

GIROLIFT Series GENERAL INFORMATION

26

A.18 REFILLING AND PRODUCT SPECIFICATIONS

Girolift 3514 Girolift 3518 Capacity (litres)

Girolift 5022 Capacity (litres)

10,5

13,5

Part

Product

Diesel engine

Shell Myrina D SAE 15W-40

Engine cooling system

Caltex Polar Antifreeze (ASTM D3306-74)

30

35

Fuel tank

Diesel fuel

125

125

Oil tank

Shell Tellus T46 DENISON HF-1

200

200

Gearbox

Shell Super Gear 90 LS SAE 90W

2.7

2.2

Differential gears

Shell Super Gear 90 LS SAE 90W

8.5

7+7

Wheel reduction gears

Shell Super Gear 90 LS SAE 90W

0.6 + 0.6

1.5 + 1.5

Turret rotation reduction gear

Shell Super Gear 90 LS SAE 90W

2.8

2.8

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


B

GIROLIFT Series SAFETY

1

Section B SAFETY INFORMATION SECTION INDEX B.01

General considerations ...................................................................... page

2

B.02

Requisites of the servicemen .....................................................................

2

B.02-1

Personal protective equipment...................................................................

3

B.03

General safety precautions .........................................................................

3

B.03-1

Working areas...............................................................................................

3

B.03-2

Precautions during work .............................................................................

3

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


B

GIROLIFT Series SAFETY

2

B.01 GENERAL CONSIDERATIONS

B.02 REQUISITES OF THE SERVICEMEN

Most accidents occurring while working, servicing or maintaining operation machines, are caused by not complying with the basic safety precautions. Therefore, it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine.

The operators who use the machine regularly or occasionally (e.g. for maintenance or transport) shall have the following requisites:

IMPORTANT If you recognise hazardous situations, you can prevent accidents!

For instance, this handbook makes use of special safety symbols to highlight potentially hazardous situations.

ATTENTION The instructions given in this handbook are the ones established by TEREXLIFT. They do not exclude other safe and most convenient ways for the machine commissioning, operation and maintenance that take into account the available spaces and means.

If you decide to follow instructions other than those given in this manual, you must: • be sure that the operations you are going to carry out are not explicitly forbidden; • be sure that the methods are safe and in compliance with the indications given in this section; • be sure that the methods cannot damage the machine directly or indirectly or make it unsafe; • contact TEREXLIFT Assistance Service for any suggestion and the necessary written permission.

health: before and during any operation, operators shall never take alcoholic beverages, medicines or other substances that may alter their psycho-physical conditions and, consequently, their working abilities. physical: good eyesight, acute hearing, good co-ordination and ability to carry out all required operations in a safe way, according to the instructions of this manual. mental: ability to understand and apply the rules, regulations and safety precautions. They shall be careful and sensible for their own as well as for the others’ safety and shall desire to carry out the work correctly and in a responsible way. emotional: they shall keep calm and always be able to evaluate their own physical and mental conditions. training: they shall read and familiarise with this handbook, its enclosed graphs and diagrams, the identification and hazard warning plates. They shall be skilled and trained about the machine use.

IMPORTANT It is recommended to take part in at least one technical training course organised by TEREXLIFT Assistance Office.

IMPORTANT

IMPORTANT

Do not hesitate to pose questions if you are in doubt! Contact TEREXLIFT: the assistance service is at your disposal. Addresses, phone and fax numbers are given in the cover and in the title-page of this manual.

Ordinary and extraordinary maintenance of the machineare quite complex from a technical point of view and should be performed by an authoirsed service centre.

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


B

GIROLIFT Series SAFETY B.02-1

PERSONAL PROTECTIVE EQUIPMENT During work, but especially when maintaining or repairing the machine, operators must wear suitable protective clothing and equipment: • Overalls or any other comfortable garments. Operators should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine •

Protective helmet when working under or in the vicinity of suspended load

Protective gloves

Working shoes

Breathing set (or dust mask)

Ear-protectors or equivalent equipment

Goggles or facial screen.

IMPORTANT Use only type-approved protective equipment in good condition.

Document 57.4400.4200 - 1st Edition 12/2002

3

B.03 SAFETY PRECAUTIONS

DANGER Read and understand the following safety instructions before servicing the machine. The following list contains safety rules which must absolutely be obeyed to prevent accidents and injuries.

B.03-1 WORKING AREA • Make sure the area all around the machine is safe. Always be aware of potential risks. • During work, keep the working area in order. Never leave objects scattered: they could hinder the machine movements and represent a danger for personnel. B.03-2 PRECAUTIONS DURING WORK • Do not walk or stop under raised loads or machine parts supported by hydraulic cylinders or ropes only. • Keep the machine handholds and access steps always clean from oil, grease or dirt to prevent falls or slips. • When entering/leaving the cab or other raised parts, always face the machine; never turn the back. • When carrying out operations at hazardous heights (over 3 meters from the ground), always use type-approved safety belts or fall preventing devices. • Do not enter/leave the machine when it is running. • Before servicing the engine, let its parts cool down. • Do not leave the driving place when the machine is running. • Neither stop nor carry out interventions under or between the machine wheels when engine is running. When maintenance in this area is needed, stop the engine, engage the parking brake and chock the wheels to prevent accidental movements. • Do not carry out maintenance or repair works without a sufficient lighting. • When using the machine lights, the beam should be oriented in order not to blind the personnel at work.

INDEX


B

GIROLIFT Series SAFETY •

• • • •

• • • • •

Before applying voltage to electric cables or components, ensure they are properly connected and efficient. Do not carry out interventions on electric components with voltage over 48V. Do not connect wet plugs or sockets. Signs and stickers shall never be removed, hidden or become unreadable. Except for maintenance purposes, do not remove safety devices, covers, guards,. Should their removal be necessary, stop the engine, remove them with the greatest care and always remember to refit them before starting the engine and using the machine again. Aleays stop the engine and disconnect the batteries before maintenance or service. Do not lubricate, clean or adjust moving parts. Do not carry out operations manually when specific tools are provided for this purpose. Absolutely avoid to use tools in bad conditions or in an improper way. Before carrying out operations on hydraulic lines under pressure (hydraulic oil, compressed air) and/or before disconnecting hydraulic components, ensure the relevant line has been previously depressurised and does not contain any hot fluid.

DANGER

• • • • •

4

that no tool, cloth or other object has been left within compartments with moving parts or in which suction and cooling air circulates. Never give orders to several people at a ime. Instructions and signs must be given by one person only. Always pay the due attention to the instructions given by the foreman. Never distract the operator during working phases or crucial manoeuvres. Do not call an operator suddenly, if unnecessary. Do not frighten an operator or throw objects by no means. After work, never leave the machine under potentially dangerous conditions.

PROTECT THE ENVIRONMENT Treatment and disposal of used oils is subject to federal, national and local laws and regulations. Collect and deliver these wastes to authorised centres.

• •

Use the assistance of a second person to handle loads weighing 30 to 50 kg. For loads over 50 kg, the use of special hoisting equipment in good condition and equipped as per enforced regulations is mandatory.

Any intervention on the hydraulic or pneumatic circuit must be carried out by authorised personnel. Before any operation on lines under pressure, release any residual pressure from the circuit. Do not use your fingers to check for pressure leaks. Fine jets of air, oil or fuel can injure you.

• • •

• •

Neither smoke nor use open flames if there is a risk of fire or close to fuel, oil or batteries. Do not leave fuel cans or bottles in unsuitable places. Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions. Carefully handle all flammable or dangerous substances. After any maintenance or repair work, make sure

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


C

GIROLIFT Series TECHNICAL OPERATING DATA

1

Section C TECHNICAL OPERATING DATA SECTION INDEX C.01

Principles of hydraulics ...................................................................... page

3

C.02

Hydraulic symbols ........................................................................................

31

C.03

Hydraulic schemes ......................................................................................

33

C.04

Electrical symbols ........................................................................................

42

C.05

Wiring diagrams 3514-3518 (up to serial no. 9261) 5022 (up to serial no. 9410) ..........................................................................

C.06

44

Wiring diagrams 3514-3518 (from serial no. 9262) 5022 (from serial no. 9411) ..........................................................................

67

C.07

Wiring diagrams - RADIO version ...............................................................

90

C.08

Wiring diagrams - AERIAL PLATFORM .....................................................

108

C.09

Wiring diagrams - 3B6 load limiter .............................................................

111

Document 57.4400.4200 - 1st Edition 12/2002

INDEX


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